Absorbent article

ABSTRACT

An absorbent article includes an absorbent core. The article has a central longitudinal axis and a central transverse axis extending perpendicular to said longitudinal axis, the absorbent article having a front end edge and a back end edge. The absorbent article has a front portion, a back portion and a crotch portion. The absorbent core includes a coherent area disposed in at least the front portion and the crotch portion. The coherent area is in an absorbent component. The core cover includes a sealing arrangement for joining the upper and lower sides in the form of at least one sealed channel. The sealed channel is free or substantially free from absorbent material. The absorbent component includes oblong high density areas extending in the longitudinal direction at least in the front portion of the absorbent article.

TECHNICAL FIELD

The disclosure pertains to an absorbent article comprising an absorbentcore which is sandwiched between a liquid-permeable topsheet and aliquid-impermeable backsheet. The absorbent core comprises an absorbentcomponent which is enclosed by a core cover.

BACKGROUND

In the field of disposable absorbent articles, such as disposableabsorbent diapers and pant-type articles, there is a general desire toprovide the absorbent articles with a snug and body conforming fit aswell as absorbency and leakage security. In addition, there is acontinuing need for improvements in particular with regard to reductionof material consumption as well as cost efficiency when manufacturingdisposable absorbent articles. There is also an increasing concern thatthe amount of material used in disposable absorbent articles is kept toa minimum from an environmental point of view. Hence, there is a desirefor disposable absorbent articles which require less raw material, withthe location of absorbent material in the article tailored towards theuser's anatomy and needs.

EP 2 949 302 A1 discloses an absorbent core which is substantially freeof cellulose fibers and consists of a plurality of discrete strips ofabsorbent material. The absorbent core has curved channel-forming areasin an absorbent core.

SUMMARY

The present disclosure is based on the insight that an absorbent articlehaving improved fit and body conformance as well as good functionalitywith regard to absorbency and leakage security, may be achieved by acombination of selected features in an absorbent core of the article.

The absorbent articles referred to herein are wearable and disposableabsorbent articles, for example in the form of open diapers, pantdiapers, belted diapers, incontinence garments, feminine hygienegarments and the like, as well as absorbent inserts which are worninside a support garment, such as a support pant or ordinary underwear.The articles are used to absorb, distribute and store various types ofbody exudates while providing a high level of comfort and a sense ofdryness to the wearer during use.

Disposable absorbent articles having good functionality, fit and bodyconformance may be achieved. Variations of the disclosure are set out inthe dependent claims.

Disclosed herein is an absorbent article comprising an absorbent coresandwiched between a liquid-permeable topsheet and a liquid-impermeablebacksheet. The article has a longitudinal direction along a centrallongitudinal axis and a transverse direction along a central transverseaxis extending perpendicular to said longitudinal axis, said absorbentarticle having a front end edge and a back end edge extending in saidtransverse direction and a first side edge and a second side edgeextending in said longitudinal direction. The absorbent article has afront portion, a back portion and a crotch portion located between saidfront portion and the back portion. The absorbent core comprises anabsorbent component, the absorbent component being enclosed by a corecover, the absorbent component comprising a coherent area, the coherentarea having an extension in at least the front portion and the crotchportion of the absorbent article and having an extension in saidtransverse direction over a full width of said absorbent componentinside said core cover. The coherent area has a front edge, a back edge,a first side edge and a second side edge and a width in the transversedirection between the first side edge and the second side edge of thecoherent area, the absorbent component having a width, the width of theabsorbent component within the coherent area being equal to the width ofthe coherent area. The coherent area comprises an absorbent componentenclosed by a core cover. The core cover comprises an upper side and alower side and a sealing arrangement for joining said upper and lowersides of the core cover in the form of at least one sealed channelextending in the longitudinal direction of the absorbent core. Thesealed channel is free or substantially free from absorbent material.The absorbent component comprises oblong high density areas of absorbentmaterial alternating with oblong low density areas of absorbentmaterial, the oblong high density areas of absorbent material and theoblong low density areas of absorbent material extending in thelongitudinal direction of the absorbent article in the front portionand/or in the crotch portion of the absorbent article and wherein theabsorbent component comprises 3-20 oblong high density areas, such asfrom 4 to 15 oblong high density areas or from 5 to 10 oblong highdensity areas.

The front, back and crotch portion of the absorbent article may eachform about a third of the length of the absorbent article. The absorbentcore may be in the crotch portion and extend at least partially into thefront and back portions of the absorbent article. The core may extendfurther into the front portion than the back portion of the absorbentarticle.

The core comprises an absorbent component enclosed by a core cover, thecore cover comprising an upper side and a lower side. Accordingly, anabsorbent component is a part of the absorbent article which may beenclosed in a core cover. The absorbent component may constitute all orpart of the absorbent core, as set out herein.

The absorbent component which is enclosed by the core cover, maycomprise both the coherent area of the absorbent core and a conformancezone or only the coherent area of the absorbent core. In the lattercase, the conformance zone may be provided as a separate component whichmay or may not be enclosed by a core cover. When enclosed by a corecover, the upper and lower sides of the core cover may or may not beattached, such as by adhesive, in areas outside the absorbent clusters.An absorbent material composition may be the same in the coherent areaand in the conformance zone. The absorbent material may compriseabsorbent cellulose fibres, such as cellulose pulp fibers. The cellulosepulp fibers may be mixed with superabsorbent polymer material. Thesuperabsorbent polymer material may be in any suitable form as known inthe art, such as in the form of particles (including granules), fibers,flakes, etc.

In the coherent area of the absorbent component, the absorbent materialis interconnected such that there are unbroken fluid distribution pathswithin the absorbent material in the longitudinal direction from thefront edge of the coherent area to the back edge of the coherent area aswell as in the transverse direction from one side edge of the coherentarea to the opposite side edge of the coherent area. The coherent areaextends at least in the front portion and the crotch portion of theabsorbent article and extends in the transverse direction over the fullwidth of the absorbent component inside the core cover. Thus, fluidswhich are absorbed by the absorbent material in the coherent area of theabsorbent component can be distributed in the core component both in thelongitudinal direction and in the transverse direction e.g., under theaction of capillary forces within the absorbent material in the coherentarea of the absorbent component. The coherent area may be framed byabsorbent material such that any channel therein stops short from thefront edge, the back edge, the first side edge and the second side edgeof the coherent area.

The back portion of the absorbent article may comprise a conformancezone with absorbent material. The conformance zone may comprise aplurality of absorbent clusters.

The coherent area of the absorbent core comprises oblong high densityareas of absorbent material extending in the longitudinal direction fromthe front end edge of the absorbent article towards the back end edge ofthe absorbent article in a front portion and/or a crotch portion of thecoherent area. The oblong high density areas are regions of theabsorbent core in which absorbent material has been accumulated toprovide absorption of body liquids where needed in the article and toprovide rigidity to the absorbent core.

The oblong high density areas may have a greater thickness than theparts of the coherent area which are not occupied by the oblong highdensity areas. Due to the accumulation of absorbent material in theoblong high density areas, the oblong high density areas have a higherbasis weight than the parts of the coherent area which are not occupiedby the oblong high density areas. The absorbent material in the oblonghigh density areas have a higher density than the parts of the absorbentmaterial in the coherent area which are not occupied by the oblong highdensity areas, such as the oblong low density areas between the oblonghigh density areas. The absorbent material in the oblong high densityareas may have any combination of greater thickness, higher basis weightand higher density than the absorbent material in parts of the coherentarea which are not occupied by the oblong high density areas.

The oblong high density areas may extend in the longitudinal directionof the absorbent article, all the way or substantially all the way fromthe front edge to the back edge of the coherent area.

A density of absorbent material may be higher in the oblong high densityareas than in the clusters in the conformance zone in the back portionof the absorbent article. The absorbent material in the oblong highdensity areas may have a greater thickness than the absorbent clustersin the conformance zone in the back portion of the absorbent article.The absorbent material in the oblong high density areas may have ahigher basis weight than the absorbent clusters in the conformance zonein the back portion of the absorbent article.

The density of absorbent material in the oblong high density areas maybe 10-90% higher, such as 20-70% higher, than in said plurality ofabsorbent clusters in said conformance zone in the back portion of theabsorbent article.

The density of absorbent material in said stiffening segment in thecrotch portion of said absorbent article may be 5-70% higher than in theoblong high density areas in the front portion of said absorbentarticle, such as 10-50% higher.

The density of the absorbent material in the oblong high density areasmay be at least 130 kg/m³ and below 300 kg/m³, such as at least 140 andbelow 210 kg/m³.

The oblong high density areas may have a width of 3-30 mm, such as 5-20mm. The oblong high density areas may have a length of from 50 mm to 400mm, such as from 70 mm to 300 mm or from 100 mm to 200 mm.

The oblong high density areas may have in combination a width of 3-30mm, such as 5-20 mm and a length of from 50 mm to 400 mm, such as from70 mm to 300 mm or from 100 mm to 200 mm and may be arranged alternatingwith low density areas having a length equal to the length of the oblonghigh density areas and a width of less than 5 mm and more than 0.5 mm,such as from 1.5 mm to 3 mm.

The oblong high density areas may have a length to width ratio of from 2to 135, such as from 5 to 100 or from 15 to 70.

The absorbent component may comprise oblong high density areas ofabsorbent material extending in said longitudinal direction at least inthe front portion and the crotch portion of said absorbent article. Theoblong high density areas may extend in said longitudinal directionsubstantially from said front edge to said back edge of said coherentarea.

The oblong high density areas are delimited in the transverse directionby oblong low density areas of absorbent material. The oblong lowdensity areas may have a width of less than 5 mm and more than 0.5 mm.The density of the absorbent material in the oblong low density areasmay be less than 50 kg/m³.

The coherent area may be a primary absorption area of the absorbentarticle and is configured to provide a major part of the absorptioncapacity of the absorbent article. The coherent area together with theconformance zone may ascertain that the liquid which reaches theabsorbent article during use is safely absorbed, distributed andretained by the absorbent core. The coherent area may have any suitableshape, such as rectangular shape, hourglass shape, etc. as known in theart.

As disclosed herein, the absorbent clusters in the conformance zone mayhave a circular, oval or polygonal shape or a mixture of differentshapes. The absorbent clusters may have the same size or may differ insize within the conformance zone. The absorbent clusters may haveindistinct or fuzzy peripheral edges and may even be interconnected bythinned edge portions of the clusters such that the absorbent clustersare perceived as being weakly connected with each other. Alternatively,the absorbent clusters may be completely separated by absorbent freechannels between the absorbent clusters.

The arrangement of absorbent material in clusters separated by thinnedareas or areas which are free or substantially free from absorbentmaterial, makes the conformance zone soft and flexible and highly bodyconforming. The thinned or absorbent free areas offer less bendingresistance than the thicker and stiffer material in the absorbentclusters.

In addition to providing a highly conformable back portion of theabsorbent article, the arrangement of absorbent material in clusterssaves material while still providing the absorbent article withappropriate absorbent capacity where needed. It has been found that byarranging the absorbent material in clusters, liquid which reaches theback portion of the article may be efficiently captured by a relativelysmall amount of absorbent material which is spread out in clusters overa part of the back portion of the absorbent article which may be reachedby liquid during use of the absorbent article. By arranging theabsorption material in clusters, the absorption material may provideadequate absorption capacity over a larger area than would have beenpossible with the same amount of absorbent material spread out in auniform layer of material. Furthermore, when compared to a back portionhaving the same amount of absorbent material spread out in an even layerover the conformance zone the clusters serve to concentrate absorbedliquid to the clusters, thereby diminishing the wet area of the backportion. Accordingly, the conformance zone as disclosed herein offersefficient supplementary absorption of a relatively smaller amount ofliquid which is not absorbed by the primary absorption material in thecoherent area of the absorbent core.

Furthermore, the clustering of the absorbent material makes the backportion of the absorbent article airy due to the non-absorbent or lessabsorbent areas between the absorbent clusters, the non-absorbent orless absorbent areas which separate the absorbent clusters thus servingas air channels in the back portion of the absorbent article. There isalso an advantageous cushioning effect of the absorbent clusters,reducing the contact surface between the absorbent article and the bodyof a wearer, in the rear portion of the absorbent article.

The conformance zone comprising the plurality of absorbent clusters maybe non-contiguous with the coherent area. The conformance zone isconsidered to be non-contiguous with the coherent area if there is adistance between the back edge of the coherent area and a front edge ofthe conformance zone. A non-contiguous conformance zone mayalternatively be described as being detached, separate or independentfrom the coherent area.

The conformance zone comprising the plurality of absorbent clusters maybe contiguous with the coherent area, at least one of the absorbentclusters extending continuously in the longitudinal direction from theback edge of the coherent area. A contiguous absorbent cluster is anabsorbent cluster which forms a continuation of the absorbent materialin the coherent area of the absorbent core. The at least one contiguousabsorbent cluster extends from the back edge of the coherent areatowards the back end edge of the absorbent article.

The absorbent clusters in the plurality of absorbent clusters may beevenly or unevenly distributed in the transverse and/or in thelongitudinal direction in the back portion of the core. Hence, theabsorbent clusters may be arranged in a staggered pattern or in anyother ordered or random pattern of evenly or unevenly distributedabsorbent clusters. Furthermore, the absorbent clusters may be partlyoverlapping.

As disclosed herein, the conformance zone may comprise from 2 to 200absorbent clusters, such as from 2 to 50 absorbent clusters, such asfrom 5 to 30 absorbent clusters.

The absorbent clusters in the plurality of absorbent clusters may becircular absorbent clusters having a diameter of from 2 to 45 mm, suchas from 5 to 20 mm.

The conformance zone may be symmetrically orientated in relation to thelongitudinal axis such that the conformance zone is mirror symmetricabout the central longitudinal axis through the absorbent article. Theconformance zone may have a triangular shape, a D-shape, a W-shape or arectangular shape, including a square shape. When triangular orD-shaped, the conformance zone has a shape which narrows in a directiontowards the back end edge of the absorbent article such that a width ofthe conformance zone adjacent the back edge of the coherent area of theabsorbent core is greater than a width of the conformance zone adjacentthe back end edge of the absorbent article. The width of the conformancezone may diminish gradually by equally sized steps, as in a triangularconformance zone. The width of the conformance zone may be constant in afront area closest to the back edge of the coherent area and diminishonly at the back end of the conformance zone, as in a D-shapedconformance zone. The width of the conformance zone may be constitutedby two or more rectangular sub-zones of different width with a moreforward sub-zone having a greater width than a more rearward sub-zone ormay have any other shape with a smaller width at the back part of theconformance zone than at the front part of the conformance zone.

A triangular or D-shaped conformance zone has been found to be inagreement with spreading patterns observed in user tests, wherein meansfor liquid absorption has been shown to be primarily needed in a centrallongitudinal area of the back portion of the absorbent core, with lessor no absorption capacity needed near the longitudinal sides of the backportion of the absorbent core.

The number of absorbent clusters in the transverse direction of theconformance zone may decrease gradually in a direction towards a backedge of the absorbent article. If the absorbent clusters are of equalsize in the transverse direction and are equally spaced apart in thetransverse direction of the article, the width of the conformance zonediminishes as the number of absorbent clusters arranged in thetransverse direction decreases.

The absorbent clusters may be of the same or generally the same size asseen in a plane defined by the transverse axis and the longitudinal axisor may be of different sizes. The size of the absorbent clusters maydiminish in a direction towards the back edge of the absorbent coreand/or in a direction from the central longitudinal axis of theabsorbent article towards the side edges of the absorbent article.

The plurality of absorbent clusters in the conformance zone may compriserod shaped clusters. The rod shaped clusters may be arranged parallel orgenerally parallel to each other in the longitudinal direction of theabsorbent article. The rod shaped clusters may be distributed in thetransverse direction over a triangular area of the absorbent article,the triangular area having its base arranged at the back edge of thecoherent area and its tip arranged on the central longitudinal axis ofthe absorbent article and facing the back edge of the absorbent core.There may be 2-20 rod shaped clusters, such as 3-10, in the conformancezone.

The back edge of the coherent area may be non-linear and may have atleast one aberration, such as one or more protrusions extending awayfrom a straight base line or a baseline having an even curvature. Theback edge of the coherent area may have the form of a baseline fromwhich evenly distributed protrusions extend in a direction toward theback end edge of the absorbent article.

The protrusions of the back edge of the coherent area may be in the formof semi-circles extending longitudinally away from the front end edge ofthe absorbent article and towards the back end edge of the absorbentarticle.

A modified circular bend stiffness may be at least 50% higher in thefront portion of the absorbent article comprising oblong high densityareas than in a conformance zone in the back portion of the absorbentarticle.

As disclosed herein, an absorbent component, including the coherentarea, may be enclosed in a core cover. The coherent area of theabsorbent component may comprise one or more sealed channels extendingin the longitudinal direction in the crotch portion of the absorbentarticle, such as a first sealed channel and a second sealed channel, the35 sealed channels having seals extending therein, the seals joining theupper and lower sides of the core cover within the sealed channels. Thesealed channels may be permanent channels, implying that the sealsjoining the upper and lower sides of the core cover remain unbrokenduring normal use of the absorbent article. Furthermore, the seals inthe sealed channels restrain the cover material and prevent theabsorbent material in the absorbent component from expanding into andclosing the sealed channels upon wetting of the absorbent component. Thechannels may be free from absorbent material.

The oblong high density areas in the coherent area may at least partlyextend along the sealed channels. This will be the case when oblong highdensity areas are arranged in the crotch portion of an absorbent articlehaving sealed channels arranged in the crotch portion.

The absorbent article may further comprise two side seams being arrangedalong longitudinal side edges of the absorbent component. In a coherentarea having two sealed channels, a center segment having a first widthis defined in the absorbent component between the sealed channels, andtwo side segments each having a second width are defined in theabsorbent component outside each channel seal between each channel sealand a corresponding one of the side seams.

The absorbent component in the crotch portion may be configured so that33-41 weight % of the absorbent material is in the center segment and25-33 weight % of the absorbent material is in each one of the sidesegments.

When defining that the total amount of absorbent material in a centersegment located between two sealed channels is generally equal to, orgreater than the total amount of absorbent material in each one of theside segments, is meant that the total weight of the absorbent materialin the center segment is generally equal to, or greater than, the totalweight of the absorbent material in each one of the side segments.

The provision of sealed channels in the absorbent component contributesto improving fit, comfort and function of the absorbent article in itswet condition. It is offered an absorbent article in which the crotchportion, and in particular a segment between two sealed channels, may beconfigured to develop an increased stiffness as compared with theremaining parts of the absorbent core. There is a well-known problemwith sagging in the crotch portion of an absorbent article as thearticle absorbs liquid which accumulates in the crotch portion. Thesagging problem will gradually increase as the amount of liquid absorbedby the article increases. An absorbent article, as disclosed herein andbeing provided with at least two sealed channels, is constructed so thatthe stiffness in the segment of the absorbent component which is locatedbetween the sealed channels increases gradually with the amount ofliquid absorbed by the article. Initially, when only a small amount ofliquid has been absorbed, the problem with sagging is negligible, andtherefore the stiffness in the center segment does not need to be high.As the amount of absorbed liquid increases, the problem with saggingincreases proportionally, and so a higher stiffness in the centersegment is desirable to counteract the weight of the absorbed liquid inthe crotch portion.

Furthermore, according to the present disclosure, absorbent sidesegments arranged between side seams of the absorbent component andsealed channels will not, at least not to any substantial extent,increase its stiffness in wet condition. The absorbent side segmentswill ensure that the total absorbent capacity in the crotch portion issufficient while remaining relatively soft and pliable, as compared tothe stiffened portion or portions located between sealed channels.According to the present disclosure, an absorbent article is obtainedhaving a reduced tendency for sagging while at the same time havingsufficient absorption capacity in the crotch portion and also beingcomfortable to wear for the user.

The core cover enclosing a stiffening segment located between two sealedchannels thus defines and limits the expansion space for the absorbentmaterial in the stiffening segment. In the absorbent articles asdisclosed herein, it is not necessary that the expansion space iscompletely closed around the stiffening segment or segments between thesealed channels, only that the swelling of the absorbent material in thestiffening segment or segments is restricted, at least in the transversedirection of the absorbent article. The ends of a stiffening segment maybe open such that fluid may pass in the longitudinal direction out ofthe stiffening segment.

The absorbent article may comprise leg elastic elements extending alongall or a part of each longitudinal side edge of the absorbent article.If one or more longitudinally extending channel is provided in thecrotch portion of the absorbent article, the leg elastic elements mayhave a greater length in the longitudinal direction of the absorbentarticle than the length of the one or more longitudinally extendingchannel.

The leg elastic elements may extend in the longitudinal direction of thearticle in the crotch portion of the absorbent article and in part ofthe front portion and/or part of the back portion of the absorbentarticle. The leg elastic elements may have a greater extension in theback portion than in the front portion.

The leg elastic elements may cooperate with features of the absorbentcomponent such as the oblong high density areas and sealed channels asdisclosed herein to promote shaping and fit of the absorbent articleduring use.

A ratio of a width of a center segment of the absorbent component asmeasured in the transverse direction between two sealed channels and adistance in the transverse direction between the leg elastic elementsmay be from 0.10 to 0.30, from 0.15 to 0.25 or from 0.18 to 0.22.

The article may comprise a waist elastic feature located in the backportion at the back end edge of the absorbent article. A waist elasticfeature, together with the leg elastic elements and the absorbentcomponent comprising a stiffening segment located between two sealedchannels and two side segments according to the present disclosurecontribute to an improved fit of the article during use. In addition toor instead of a waist elastic feature in the back portion of theabsorbent article, a waist elastic feature may be located in the frontportion of the absorbent article. Waist elastic features may extend onlypartly along the front and/or the back end edge or may extend the fulllength of the front and/or the back end edge, i.e. from the first sideedge to the second side edge of the absorbent article.

A core cover as disclosed herein may be formed by a separate upper corecover layer forming the upper side of the core cover and a separatelower core cover layer forming the lower side of the core cover, theupper and lower core cover layers together enclosing the absorbentcomponent. A sealing arrangement may be provided for joining the upperand lower sides of the core cover. The disclosure is not limited to corecovers comprising two separate core cover layers. The core cover may beformed from a single material layer. In such case the absorbentcomponent may be enclosed by one core cover layer which is wrappedaround the absorbent component or which is formed as a tubular structureinto which the absorbent component is inserted. Furthermore, the corecover may be made from more than two core cover layers. The core covermay be sealed only in the longitudinal direction of the absorbentarticle, leaving the core cover open in both a front end of the corecover and in a back end of the core cover. Alternatively, the core covermay be sealed at one or both of the front end and the back end of thecore cover. In the latter case, the absorbent component is completelyenclosed inside the core cover.

The basis weight of the core cover material may be in the range of from5 g/m² to 20 g/m².

The core cover material may be made of thermoplastic polymer material,such as polyolefin, polyesters, polyamide and combinations thereof. Thecore cover material may be nonwoven material. The nonwoven material maybe made of thermoplastic polymer material fibers or filaments. Thenonwoven layer may be formed by any of a variety of different processes,such as spunbonding, airlaying, meltblowing or bonded carded webformation processes. The nonwoven layer may be made of co-formed laminaof nonwoven materials such as an SMS (spunbond/meltblown/spunbond)nonwoven material or an SS (spunbond/spunbond) nonwoven material. Thethermoplastic polymer materials in the nonwoven layer may bepolypropylene or bicomponent fibers of polypropylene and polyethylene,or of a combination of such materials.

An absorbent component as disclosed herein may be constituted by onesingle absorbent component layer which is wrapped in a core cover havingan upper side and lower side. Absorbent components comprising two ormore layers are also contemplated for the absorbent cores as disclosedherein.

The absorbent component may have a rectangular shape. A rectangularabsorbent component may have the advantage of being easy to manufactureand enclose by a core cover.

One or more channel may be arranged in the absorbent component such asone to five channels. The channel or channels may be arranged in thelongitudinal direction of the absorbent article. The channel or channelsmay be free from absorbent material and the upper and lower sides of thecore cover may be joined to each other by one or more channel sealsbeing arranged in the channel or channels to form sealed channels. Iftwo or more sealed channels are present in the coherent area, stiffeningsegments are formed between each two adjacent sealed channels.

The absorbent component may comprise a mixture of absorbent cellulosefibers, such as cellulose pulp fibers and superabsorbent polymermaterial in the form of particles, granules, fibers, flakes, etc. Theabsorbent material in the absorbent component, at least in the crotchportion, may be constituted by 50-100 weight % superabsorbent materialand 0-50 weight % pulp material, or 70-100 weight % superabsorbentmaterial and 0-30% pulp material.

The composition of the absorbent material may be the same in thecoherent area and in the conformance zone. Hence, a mixture ofsuperabsorbent material and pulp material may be the same in thecoherent area and in the conformance zone.

The total absorbent capacity per cubic centimeter of the coherent areaof the absorbent component in dry condition may be at least 15 g/cm³, orat least 25 g/cm³ or at least 35 g/cm³.

The pulp material in the coherent area of the absorbent component mayhave a basis weight which is in the interval of 50-400 g/m² and thesuperabsorbent material may have a basis weight which is in the intervalof 100-900 g/m².

The thickness of the coherent area of the absorbent component in drycondition, measured with an applied pressure of 0.5 kPa, may be in therange of from 1.0 to 5.5 mm or from 2.0 to 4.5 mm. A representative meanvalue may be obtained by measuring on several parts of the absorbentcomponent.

The absorbent article may comprise a single core layer.

The absorbent component may be formed using an air forming process, suchas an air forming process carried out on an air forming drum, alsoreferred to as a vacuum forming drum. The air forming drum operates byapplication of internal suction in the forming drum 30 to draw flows ofair suspended absorbent material into forming molds arranged on thesurface of the forming drum.

The forming drum may have several forming molds arranged on the outersurface into which the absorbent material is deposited for continuouslyforming absorbent 35 components. The shape and size of the forming moldsdetermine the shape and size of the absorbent components. Each formingmold has a foraminous air permeable bottom on which the air suspendedabsorbent material is collected and accumulated as the air is drawn offinto the interior of the forming drum. The amount of material depositedin different parts of the mold may be controlled by controlling the airflow through the foraminous bottom. To this end, the foraminous bottomof the mold may have different air permeability in different portions ofthe mold which may be accomplished by arranging masking plates indifferent parts of the mold and/or by shaping the foraminous bottom tocreate a mold with varying depth, corresponding to an absorbentcomponent having different thickness in different parts. A first part ofthe mold may be arranged to produce the coherent area of the absorbentcomponent as set out herein. The bottom of the first part of the moldmay then comprise grooves corresponding to where oblong high densityareas of accumulated material are to be formed which will form oblonghigh density areas in the coherent area of the absorbent componentand/or one or more blocked areas where channels are to be formed in theabsorbent component. A second part of the mold may be arranged toproduce the conformance zone and may have a blocking plate havingopenings arranged therein, the openings being arranged in locationswhere the absorbent clusters are to be formed and having a shape andsize corresponding to the shape and size of the absorbent clusters. Thepresence of blocking plates in the second part of the mold also servesto decrease the air permeability in this area of the mold, which causesa greater part of the air flow and concomitantly a greater part of theair suspended absorbent material to be drawn towards and collected inthe first part of the forming mold.

The disclosure may be varied within the scope of the appended claims.For example, the materials and dimensions used for the different layersforming an absorbent article as disclosed herein may be varied, asindicated above. The absorbent article may further include any usefulcomponent or feature as known in the art such as fluid acquisition anddistribution components, leg elastics, standing gathers, crotch andwaist elastics, side panels, fastening systems, wetness indicators, skincare agents, disposal means, etc as known in the art and depending ofthe type of absorbent article intended.

BRIEF DESCRIPTION OF THE DRAWINGS

Preferred exemplary embodiments of the absorbent articles as disclosedherein will be further explained hereinafter with reference to theappended drawings wherein:

FIG. 1 shows a view from above of an absorbent article in the form of adiaper;

FIGS. 2A-2I show different core configurations;

FIG. 3 shows a cross-section taken along the line IV-IV in FIG. 2E;

FIG. 4 shows a cross-section taken along the line V-V in FIG. 2E; and

FIG. 5 shows a cross-section taken along the line VI-VI in FIG. 2E.

DETAILED DESCRIPTION OF PREFERRED EXEMPLARY EMBODIMENTS

Different aspects of the present disclosure will be described more fullyhereinafter with reference to the enclosed drawings. The embodimentsdisclosed herein can, however, be realized in many different forms andshould not be construed as being limited to the aspects set forthherein.

It is to be understood that the drawings are schematic and thatindividual components, such as layers of material are not necessarilydrawn to scale.

With initial reference to FIG. 1, there is shown an absorbent article 1in the form of a baby diaper. The absorbent article 1 is shown in FIG. 1in an unfolded and flat state with all elastic elements in an extendedstate.

The absorbent article 1 is seen from the surface which will be facing awearer's body when the article is being worn and comprises aliquid-permeable topsheet 3, a liquid-impermeable backsheet 4 and anabsorbent core 5 which is sandwiched between the topsheet 3 and thebacksheet 4. The topsheet 3 is arranged at the inner or wearer-facingsurface of the absorbent article 1, whereas the backsheet 4 is arrangedat the outer or garment-facing surface of the absorbent article 1.Furthermore, as illustrated in FIG. 1, both the topsheet 3 and thebacksheet 4 may extend laterally outside of the absorbent core 5 alongthe entire perimeter of the absorbent article 1. Alternatively, thetopsheet 3 and the backsheet 4 may be generally coextensive with theabsorbent core 5 or only one of the topsheet 3 and the backsheet 4 mayextend outside the perimeter of the absorbent core 5. It is alsoconceivable that the topsheet 3 and the backsheet 4 extend outside ofthe absorbent core only along parts of the perimeter of the absorbentarticle, such as only along the side edges or only along one or both endedges or along the side edges and only one of the end edges.

The absorbent core shown in FIG. 1 has a rectangular design. However, asset out herein, the disclosure is not limited to this design and it isto be understood that the absorbent core may have any useful shapewithin the scope of the invention.

The topsheet 3, backsheet 4 and the absorbent core 5 may consist of anymaterials suitable for their purposes, as will be discussed in furtherdetail below.

As shown in FIG. 1, the absorbent article 1 has a longitudinal directionalong a central longitudinal axis y1 and a transverse direction along acentral transverse axis x1, which is perpendicular to the longitudinalaxis y1. Furthermore, the absorbent article 1 may be defined as beingdivided into a front portion 6 having a length l₂, a back portion 7having a length l₃ and a crotch portion 8 having a length 11. The frontportion 6 has a front waist edge constituting a front end edge 19 of theabsorbent article 1 and the back portion 7 has a back waist edgeconstituting a back end edge 21 of the absorbent article 1. Leg edgesare formed by longitudinally extending side edges 32,33 of the absorbentarticle 1. The front portion 6 is the part of the absorbent articlewhich is intended to be oriented in a direction towards the belly of thewearer during use of the absorbent article 1 and the back portion 7 isthe part of the absorbent article which is intended to be oriented in adirection towards the buttocks of the wearer.

The absorbent article 1 in FIG. 1 is an open-type diaper having frontfastener tabs 23, 24 extending from the side edges 32, 33 at the frontend edge 19 of the absorbent article 1 and back fastener tabs 25, 26extending from the side edges 32, 33 at the back end edge 21 of theabsorbent article 1. When putting on the absorbent article 1 on awearer, the back fastener tabs 25, 26 are brought forward towards thewearer's belly and are attached with fastener elements 27, 28, such ashook-type fastener elements onto mating fastener elements 29, 30, suchas loop-type fastener elements which are provided on the front fastenertabs 23, 24. In the diaper shown in FIG. 1, the front fastener tabs aremade of loop-type material, such that no separate fastener elements needto be provided. It is to be understood that male fasteners, such ashook-type fasteners may instead be placed at the front of the articlewhile female fasteners may be placed at the back of the article.Furthermore, the fastening arrangement may differ from that shown in theFigs. and may be of any useful kind as known in the art. Accordingly,fastener belts, girdles, adhesive fastening systems, etc. may be used.It should also be noted that the fastening system is optional to theabsorbent article 1, as the article may be designed for use as anabsorbent insert, worn inside a pair of supportive pants or ordinaryunderpants. Such articles may be provided with fastening adhesivearranged on the outer surface of the backsheet, to allow the article tobe fastened inside the pants. Furthermore, the absorbent article may bea pant-type article which is provided in a pre-assembled configuration,with closed side seams. Such articles may nevertheless be provided witha fastening system, to allow the article to be opened and reclosed.

The absorbent core 5 comprises an absorbent component 50 which issandwiched between an upper core cover side 11 and a lower core coverside 12. The core cover is a component of the absorbent article 1 whichis provided in addition to the topsheet 3 and the backsheet 4. Theabsorbent component 50 has a front edge 52 and a back edge 22.

The absorbent component 50 comprises a coherent area 51 which isdisposed forward in the absorbent article 1 with a forward part of thecoherent area 51 being located in the front portion 6 and a rearwardpart of the coherent area 51 being located in the crotch portion 8 ofthe absorbent article 1 and optionally extending also into the backportion 7 of the absorbent article 1. The coherent area 51 has a frontedge 52 and a back edge 53. As can be seen in FIG. 1, the width of theabsorbent core 5 within the coherent area 51 is defined by the width ofthe coherent area 51. The back portion 7 of the absorbent article 1comprises a conformance zone 55 which is placed behind the coherent area51 as seen in a direction towards the back end edge 21 of the absorbentarticle 1.

The coherent area 51 of the absorbent core 5 comprises oblong highdensity areas 60 extending in the longitudinal direction within thematerial in the front portion of the coherent area 51 towards the backend edge 21 of the absorbent article 1. The oblong high density areas 60are regions of the absorbent core 5 in which absorbent material has beenaccumulated such that longitudinally extending striations are formed inthe material of the coherent area 51. The number of oblong high densityareas in FIG. 1 is 11, but may be varied as disclosed herein. Thedensity of the absorbent material in the oblong high density areas 60may be at least 130 kg/m³ and below 300 kg/m³. The oblong high densityareas 60 may have a width of 3-30 mm, such as 5-20 mm. The oblong highdensity areas 60 alternate with low density areas of absorbent material.The low density areas may have a width of less than 5 mm and more than0.5 mm. The density of the absorbent material in the low density areasmay be less than 50 kg/m³.

The conformance zone comprises a plurality of absorbent clusters 56. Theabsorbent clusters 56 may have any suitable shape such as a circular,oval or polygonal shape. The absorbent clusters may all have the samesize and shape or may differ in size or shape or may differ both in sizeand shape.

In FIG. 1, the plurality of absorbent clusters 56 are shown as aplurality of generally circular accumulations of absorbent materialwhich are arranged in a staggered pattern over a triangular area 57 ofthe absorbent component 50. The number of absorbent clusters 56 in thetransverse direction of the conformance zone 55 decreases gradually in adirection towards the back edge 22 of the absorbent component 50.

The conformance zone 55 as shown in FIG. 1 is non-contiguous with thecoherent area 51 of the absorbent component 50 as the conformance zone55 is arranged at a distance from the coherent area 51. The triangulararea 57 in which the absorbent clusters 56 are arranged has its base 58arranged at a distance from the back edge 53 of the coherent area 51 andits tip 59 arranged on the central longitudinal axis y1 of the absorbentarticle and facing the back end edge 21 of the absorbent article 1.

Alternatively, the conformance zone may be contiguous with the coherentarea of the core component. Such configurations are disclosed in thenon-limiting examples illustrated in FIGS. 2D, 2E, 2F and 2H which showat least one of the absorbent clusters extending continuously in thelongitudinal direction from the back edge 53 of the coherent area 51.

In the absorbent article 1 as shown in FIG. 1, the conformance zone 55is enclosed by the upper and lower sides of the core cover 11, 12 andforms part of the absorbent component 50. The planar shape and size ofthe absorbent component is defined by the planar shape and size of thecore cover. As disclosed herein, the core cover may be formed by twoseparate sheets of material which are sealed at least along theirlongitudinally extending side edges and optionally also along one orboth of the transversely extending end edges. Alternatively, the corecover may be formed by a bi-folded sheet of material which may be foldedin the longitudinal direction and sealed at least along the side edgeswhich are opposite to the fold.

As illustrated in the figures, the absorbent clusters 56 may be evenlydistributed in the transverse and/or in the longitudinal direction ofthe absorbent article 1. FIGS. 1, 2A, 2B, 2E and 2G show conformancezones 55 having absorbent clusters 56 which are evenly distributed bothin the transverse and in the longitudinal direction. FIGS. 2C, 2D, 2Fand 2H show conformance zones 55 having absorbent clusters 56 which areevenly distributed in the transverse direction. In all of the absorbentcomponents illustrated in the figures, the conformance zone 55 issymmetrically orientated in relation to the longitudinal axis of theabsorbent component 50 and, thus, of the absorbent article 1.

The coherent area 51 of the absorbent component 50 which is shown inFIG. 1 comprises oblong high density areas 60 extending in thelongitudinal direction in a front portion of the coherent area 51.

The density of absorbent material may be higher in the oblong highdensity areas 60 than in the plurality of absorbent clusters 56 in theconformance zone 55 in the back portion 7 of the absorbent article 1.

The absorbent component 50 which is shown in FIG. 1 is formed with twolongitudinally extending and generally straight sealed channels 9,10 inwhich the upper core cover side 11 is joined to the lower core coverside 12 by seals extending along the sealed channels 9,10. The seals maybe provided as bond lines consisting of bonding elements arranged in abond pattern. A width of each bond line may be less than a width of thecorresponding sealed channel 9, 10 in which the bond line is arranged.Thereby, a slack is formed in the core cover material between the edgeof the bond line and the edge of the sealed channel in which the bondline is placed. Such slack may be provided to allow expansion room forthe absorbent material arranged on either side of the bond lines. Theslack may be smaller on the inner side of each sealed channel 9,10 whichis facing towards the centre of the absorbent article, and larger on theouter side of each sealed channel 9,10 which is facing towards the sideedges of the absorbent article 1.

As set out herein, the disclosure is not limited to a core wrapcomprising two core cover layers. The core cover may be of one singlematerial layer. The absorbent component may be enclosed by one corecover layer folded in two, or enclosed by a continuous core cover sheet,thereby providing upper and lower core cover sides for wrapping theabsorbent component.

The upper core cover side 11 and the lower core cover side 12 may beattached to each other by any useful means as known in the art, forexample, by thermo-mechanical bonding, such as thermo-sealing,ultrasonic bonding, an adhesive or adhesives, stitching or the like, orcombinations of the same.

The sealed channels 9,10 constitute sections of the absorbent component50 which are free from absorbent material. Absorbent free channels maybe obtained by manufacturing the absorbent component 50 using a matforming process during which absorbent material is omitted from theareas which correspond to the sealed channels 9,10. In this manner, noabsorbent material will be present in the sealed channels 9,10. Thepresence of absorbent material in the sealed channels 9,10 maynegatively influence the strength of the seals between the upper andlower core cover sides 11, 12 and should be avoided.

As shown in FIG. 1, the absorbent component 50 may be divided into astiffening segment 13 located centrally in the crotch portion 8 betweenthe sealed channels 9,10 and two side segments 14 a, 14 b in the crotchportion 8. The sealed channels 9,10 are consequently configured so thatthey separate the three segments 13, 14 a, 14 b from each other in thecrotch area 8.

The absorbent component 50 may be generally rectangular and may comprisetwo generally straight sealed channels 9, 10 which extend generallyparallel to the longitudinal axis y1. The seals joining the upper andlower core cover sides 11, 12 have a corresponding first channel sealingwidth w1 and a second channel sealing width w2. The disclosure is notlimited to a rectangular absorbent component 50 and generally straightsealed channels 9, 10, i.e. other geometrical configurations may beused.

Furthermore, the stiffening segment 13 is defined in the absorbentcomponent 50 between the sealed channels 9, 10. The two side segments 14a, 14 b are defined in the absorbent component 50 outside each sealedchannel 9, 10. More precisely, the first side segment 14 a is positionedbetween the first sealed channel 9 and a first side seam 15, whereas thesecond side segment 14 b is positioned between the second sealed channel10 and a second side seam 16. The side seams 15, 16 are configured forjoining the upper core cover side 11 to the lower core cover side 12,suitably by means of ultrasonic welding or other relevant technologiesas described above with reference to the seals joining the upper coverside 11 and the lower cover side 12 in the sealed channels 9, 10.Furthermore, the side seams 15, 16 extend along each side of theabsorbent component 50, inward of and along a first side edge 17 and asecond side edge 18 of the absorbent component 50.

As mentioned, the length 11 of the crotch portion 8 may be equal to thelength of the sealed channels 9, 10, i.e. the sealed channels 9, 10 maybe arranged only in the crotch portion 8. However, the side seams 15, 16may not just be positioned along the crotch portion 8 but may alsoextend into the front portion 6 and/or the back portion 7 as set out inmore detail below.

The absorbent article 1 in FIG. 1 also has leg elastic elements 30,31extending along each longitudinal side edge 32,33 of the absorbentarticle 1. The leg elastic elements 30,31 have a greater length in thelongitudinal direction than the length of the sealed channels 9, in thelongitudinal direction. Accordingly, the leg elastic elements have anextension not only in the crotch portion 8 but also in a part of thefront portion 6 and the back portion 7. The leg elastic elements 30, 31have a greater extension in the back portion 7 than in the front portion6, as seen in FIG. 1.

The absorbent article 1 also has a waist elastic element 34 located inthe back portion 7 close to the back end edge 21 of the absorbentarticle 1. It is to be understood that also the front end edge 19 may beprovided with waist elastic, if desired.

The leg elastic elements and the waist elastic element are optionalfeatures of an absorbent article as disclosed herein.

As disclosed herein, the absorbent component 50 is formed with a sealingarrangement which is constituted by the two sealed channels 9, 10 andthe two side seams 15, 16. The sealing arrangement is configured sothat, in the crotch portion 8, the absorbent component 50 is dividedinto a centrally arranged stiffening segment 13 and two side segments 14a, 14 b.

As disclosed herein, the absorbent material may comprise a mixture ofcellulose pulp material and superabsorbent material. The absorbentcomponent 50 may be configured so that the total amount of absorbentmaterial of the stiffening segment 13 between the sealed channels 9, 10is generally equal to or greater than the amount of absorbent materialin either one of the side segments 14 a, 14 b between each sealedchannel 9, 10 and the corresponding side seam 15, 16. This means thatthe available space for expansion of the absorbent material in thestiffening segment 13, as the absorbent article 1 becomes wet as itabsorbs liquid during use, is less than a corresponding availableexpansion space for each side segment 14 a, 14 b. This will lead to asituation in which the stiffening segment 13 will be stiffer than theside segments 14 a, 14 b when the absorbent article is in its wetcondition. The stiffened central stiffening segment 13 counteracts thetendency of the wet article to sag and hang down in the crotch portion8.

The expression “generally equal” as used above for describing the amountof absorbent material in the stiffening segment 13 as compared with theside segments 14 a, 14 b should be understood as allowing for slightvariations in the amount of absorbent material in the order ofapproximately ±5% in any part of the crotch portion 8.

A width of the stiffening segment 13 may be defined between the sealedchannels 9, 10 and a width of the absorbent component 50 may be definedbetween the first and second side edges 17, 18 of the absorbentcomponent 50. The ratio of the width of the stiffening segment 13 andthe width of the absorbent component 50 may be in the range of from 0.25to 0.45.

As disclosed herein, various types of materials may be used for theabsorbent article 1. The topsheet 3 which is arranged to face the wearerof the absorbent article 1 when the article is being worn may compriseor consist of a fluid permeable nonwoven fabric, film, mesh or foam. Thetopsheet may be made from thermoplastic material, such as thermoplasticsynthetic fibers, film or netting. The topsheet 3 may be sufficientlyliquid-permeable to allow discharged body fluids to penetrate throughthe thickness of the topsheet 3. Also, the topsheet 3 may suitably bemanufactured from a material which is compliant and soft-feeling to theskin of the wearer. The topsheet 3 may consist of a single layer or mayhave a laminate structure comprising a plurality of layers, for example,two or more layers. The layers may be made of the same material, or someor all of the layers may be made of different materials.

The layer of the topsheet 3 or, for the case of a laminate structure,one, some, or all layers of the topsheet may be made of a single web ofmaterial or may have portions made of different materials, e.g., withindifferent parts of the wearer-facing surface of the topsheet.

The layer of the topsheet 3 or, for the case of a laminate structure,one, some or all layers of the topsheet may be a nonwoven material, aperforated plastic film, a plastic or textile mesh, or a liquidpermeable foam layer. The layer of the topsheet 3 or, for the case of alaminate structure, one, some or all of the layers of the topsheet maybe, for example, a hydrophilic, non-apertured nonwoven web of fibers,such as natural fibers, e.g., cotton or pulp fibers, synthetic fibers,e.g., polyester or polypropylene fibers, or a combination of thesefibers. The topsheet may have a basis weight in the range of 8-40 g/m².However, the disclosure is not limited to topsheets having this basisweight.

Furthermore, the backsheet 4 may be constituted by a liquid-impermeablelayer such as a polymeric film, for example a film of polyethylene orpolypropylene. The backsheet 4 may be breathable. The materials whichmay be used for the backsheet 4 include thin and flexible fluidimpermeable plastic films, or fluid impermeable nonwoven materials,fluid impermeable foams and fluid impermeable laminates. The backsheet 4may be formed by a single layer, but may alternatively be formed by amulti-layered structure, i.e. a laminate, wherein at least one layer isfluid impermeable. Furthermore, the backsheet 4 may be elastic in anydirection. Furthermore, the backsheet 4 may have a laminate structurecomprising a liquid barrier sheet and a nonwoven layer arranged on topof each other (not shown in detail in the drawings), wherein thenonwoven layer is arranged at an outer side away from the wearer of theabsorbent article 1 when worn.

The nonwoven layer may be made of thermoplastic polymer material fibersor filaments. The nonwoven layer may be formed by any of a variety ofdifferent processes, such as spunbonding, airlaying, meltblowing orbonded carded web formation processes. The nonwoven layer may be made ofan SMS (spunbond/meltblown/spunbond) or SS (spunbond/spunbond) nonwovenmaterial of polypropylene or bicomponent fibers of polypropylene andpolyethylene, or of a combination of such materials. The nonwoven layermay have a basis weight in the range of 5-40 g/m².

The liquid barrier sheet may be made of a plastic material, for examplea thermoplastic film material, and/or a nonwoven material. For example,the liquid barrier sheet may be formed as a plastic layer, e.g., athermoplastic layer, or a plastic film, e.g., a thermoplastic film.Forming the liquid barrier sheet of a plastic material, such as athermoplastic film material, allows for a particularly good printabilityof the liquid barrier sheet. The liquid barrier sheet may also containpaper fibers. The liquid barrier sheet may be a liquid impermeable,breathable or non-breathable layer. The liquid barrier sheet may consistof a single layer or have a laminate structure with a plurality oflayers, e.g., two or more layers, three or more layers, or four or morelayers. The layers of the liquid barrier sheet may be laminated, bondedor attached to each other, for example, by thermo and/or mechanicalbonding, such as thermo-sealing, ultrasonic bonding, such as ultrasonicwelding, an adhesive or adhesives, stitching or the like. The liquidbarrier sheet may be a breathable microporous film. The microporous filmmay be made of a material comprising at least two basic components,namely a thermoplastic elastomeric polyolefin polymer and a filler.These components and, in some embodiments, additional other componentsmay be mixed together, heated and subsequently extruded into amono-layer or multi-layer film using any one of various film-producingprocesses, such as cast embossed, chill and flat cast, and blown filmprocesses.

Regarding the choice of materials for the various layers in theabsorbent article, the materials may be chosen with consideration forthe bonding processes used when forming seals in between components ofthe absorbent article, such the seals in the sealed channels and theside seams. For example, if ultrasonic welding is chosen for joining theupper and lower core cover sides, the materials for the core cover maybe chosen such that they can form a secure bond during ultrasonicwelding, e.g. by at least one of the upper and lower side of the corecover comprising or consisting of thermoplastic polymer material.

The absorbent core 5, includes the absorbent component 50 and mayinclude further absorbent components such as components which provideliquid acquisition and liquid distribution. The absorbent core isdisposed between the topsheet 3 and the backsheet 4 to absorb theliquid, such as urine or other bodily fluids, which has passed throughthe topsheet 3. The absorbent component 50 may be a single-layerstructure or may be a layered structure, e.g. within the coherent area.The absorbent component 50 may comprise suitable amounts ofsuperabsorbent material. Such superabsorbent material is well known inthe field of absorbent articles, and is constituted by a water-swellableand water-insoluble material which is capable of absorbing largequantities of fluid upon formation of a hydrogel. The absorbentcomponent may contain superabsorbent material in the form of fibers orparticles of absorbent polymer material. For example, the superabsorbentmaterial may be surface cross-linked, partially neutralizedpolyacrylates. The superabsorbent material, e.g., the superabsorbentfibers or particles, may be mixed with other absorbent or liquid uptakematerial or materials, such as cellulose fluff pulp, and/or arranged inpockets or layers in the absorbent component 50. The amount ofsuperabsorbent material and pulp in the absorbent component 50 may befrom 0 to 50 weight % pulp fibers and from 50 to 100 weight %superabsorbent material, or from 0 to 30 weight % pulp fibers and from70 to 100 weight % superabsorbent material.

The absorbent component 50 may further comprise components for improvingproperties of the absorbent core 5, such as core integrity and strength.For example, the absorbent component 50 may comprise a binder orbinders, such as binder fibers. Resilient fibers, chemically stiffenedfibers, etc. may be present in the absorbent component to counteractwet-collapse of cellulosic fibers. Such fibers may also be useful inretaining a fluid transporting capillary network in the absorbentcomponent so that absorbent fluid may be distributed in the absorbentcomponent and be absorbed by superabsorbent material also in parts ofthe absorbent component outside the initial wetting area of theabsorbent article.

The core cover 11,12 may be formed by a separate upper core cover 11layer and a separate lower core cover 12 layer. However, the disclosureis not limited to a core cover comprising two separate core coverlayers. The core cover 11,12 may also be made of one single materiallayer. The absorbent component 50 may be enclosed by one core cover11,12 layer which is folded in two and sealed along the open edges, ormay be enclosed by a continuous, tubular core cover sheet, therebyproviding upper 11 and lower core cover 12 sides for wrapping theabsorbent component 5 a,5 b,5 c. The basis weight of the core cover11,12 material may be in the interval of from 5 g/m² to 20 g/m². Thecore cover 11,12 material may be made of thermoplastic polymer material.The core cover material may be nonwoven material. The nonwoven materialmay be made of thermoplastic polymer material fibers or filaments. Thenonwoven layer may be formed by a variety of different processes, suchas spunbonding, airlaying, meltblowing or bonded carded web formationprocesses. The nonwoven layer may be made of an SMS(spunbond/meltblown/spunbond) or SS (spunbond/spunbond) nonwovenmaterial of polypropylene or bicomponent fibers of polypropylene andpolyethylene, or of a combination of such materials.

Furthermore, the various layers and components of the absorbent article1 may be attached by means of adhesive material, as known in the art.Such adhesive is not shown in the drawings.

One or more additional layers may be provided in the absorbent article1. For example, an acquisition layer may be arranged between theabsorbent component 50 and the topsheet 3. Such an additional layer mayfor example be in the form of an airlaid layer, a spunlace layer, ahigh-loft fiber material, an open-cell or perforated foam or any othertype of material layer or combination of layers which may be used in anabsorbent article to act as a liquid handling layer providing functionssuch as liquid acquisition, liquid absorption and liquid distribution. Aliquid acquisition layer is adapted to quickly receive and temporarilystore discharged liquid before the liquid can be absorbed by theabsorbent component. Such acquisition layer may be composed of forexample airlaid nonwoven, spunlace nonwoven, high loft nonwoven or foammaterials. An airlaid nonwoven may be produced wood pulp fluff fiberswhich are dispersed and suspended in a fast-moving air stream andcondensed onto a moving screen by means of pressure and vacuum.

With reference again to FIG. 1, each sealed channel 9, 10 may have alength 11 which corresponds to the longitudinal extension of the crotchportion 8. Each one of the sealed channels 9, 10 may have a length 11which is between 5-50%, such as 10-50%, such as 28-38%, of the totallength l of the absorbent article 1. Furthermore, each channel sealing9, 10 may have a length 11 which is between 10-60%, such as between20-60%, such as between 30-50%, of the length of the absorbent component50.

A further parameter is the positioning of the sealed channels 9, 10 inthe longitudinal direction of the absorbent article 1.

The position of the sealed channels 9, 10 in the longitudinal directionof the absorbent article 1 may be chosen so that each channel 9, 10terminate at a distance from the front end edge 19 of the article 1which is between 15-40%, such as between 22-25%, of the total length lof the article 1.

Furthermore, the topsheet may comprise at least one additive materialsuch as a skin 35 care composition. The additive may be located on partsof the topsheet which are disposed along the longitudinal side edges 32,33 of the absorbent article 1 and/or along the longitudinal side edges17, 18 of the absorbent component 50. An advantage with such placementof the additive material, is that as the parts of the absorbent article1 which are arranged along the side edges normally will be closer to thebody of the wearer of the absorbent article 1 than a longitudinallycentral part of the absorbent article 1, the skin care benefits of theadditive may be obtained without the additive interfering with fluidacquisition through the topsheet 3 in the central part of the absorbentarticle 1.

FIGS. 2A-2I illustrate absorbent components 50 having differentcombinations of features. The absorbent components 50 shown in theexamples of FIGS. 2A-2I should not be considered to be limiting to theabsorbent articles as disclosed herein, as it should be understood thatone or more features of the coherent area 51 in any one of FIGS. 2A-2Ican be freely combined with features of the conformance zone 55 in anyother of FIGS. 2A-2I. Furthermore, it is to be understood that theabsorbent component may have uniform composition, such as a uniformmixture of cellulose fluff pulp and superabsorbent material or may becomposed of sub-layers having different composition. The absorbentcomponent may have different composition in different zones of the areaof the absorbent component or of the area of any sub-layer in theabsorbent component.

The absorbent components 50 in FIGS. 2A-2I may be used in the absorbentarticle in FIG. 1 or in any other absorbent article as disclosed herein.

With reference to FIG. 2A, the coherent area 51 of the absorbentcomponent 50 is a layer of absorbent material having uniform thickness.Two sealed channels 9, 10 are arranged in the coherent area 51, asdisclosed herein. The sealed channels 9, 10 may optionally besupplemented by side seals as disclosed herein. The conformance zone 55is a non-contiguous conformance zone 55 which is composed of circularabsorbent clusters 56 arranged in a regular, evenly distributed patternover a rectangular area of the absorbent component 50.

With reference to FIG. 2B, the coherent area 51 of the absorbentcomponent 50 is a layer of absorbent material having oblong high densityareas 60 arranged therein. The oblong high density areas 60 extendgenerally all the way from the front edge 52 of the coherent area 51 tothe back edge 53 of the coherent area 51. Two sealed channels 9, 10 arearranged in the coherent area 51, as disclosed herein. The sealedchannels 9, 10 may optionally be supplemented by side seals as disclosedherein. The conformance zone 55 is a non-contiguous conformance zone 55which is composed of circular absorbent clusters 56 arranged in aregular, evenly distributed pattern over a triangular area of theabsorbent component 50.

With reference to FIG. 2C, the coherent area 51 of the absorbentcomponent 50 is a layer of absorbent material having uniform thickness.Two sealed channels 9, 10 are arranged in the coherent area 51, asdisclosed herein. The sealed channels 9, 10 may optionally besupplemented by side seals as disclosed herein. The conformance zone 55is a non-contiguous conformance zone 55 which is composed of rod-shapedabsorbent clusters 56 arranged spaced apart in the transverse directionand in parallel to each other in the longitudinal direction over arectangular area of the absorbent component 50.

With reference to FIG. 2D, the coherent area 51 of the absorbentcomponent 50 is a layer of absorbent material having uniform thickness.The conformance zone 55 is a contiguous conformance zone 55 which iscomposed of rod-shaped absorbent clusters 56 arranged spaced apart inthe transverse direction and in parallel to each other in thelongitudinal direction over a rectangular area of the absorbentcomponent 50. The rod-shaped absorbent clusters 56 extend in thelongitudinal direction from the back edge 53 of the coherent area 51 andform continuations of the coherent area 51. Hence, the back edge 53 ofthe coherent area 51 constitutes a straight base-line from which therod-shaped absorbent clusters 56 extend in a direction towards the backend edge (not shown in the figure) of the absorbent article.

With reference to FIG. 2E, the coherent area 51 of the absorbentcomponent 50 is a layer of absorbent material having oblong high densityareas 60 arranged therein. The oblong high density areas 60 extend inthe front portion of the coherent area 51, generally from the front edge52 of the coherent area 51 to the front ends of two sealed channels 9,10 which are arranged in the coherent area 51, as disclosed herein. Thesealed channels 9, 10 may optionally be supplemented by side seals asdisclosed herein. The conformance zone 55 is a contiguous conformancezone 55 which is composed of circular absorbent clusters 56 arranged ina regular, evenly distributed pattern over a triangular area of theabsorbent component 50. The back edge 53 of the coherent area 51 isnon-linear and may be seen as a straight baseline from which evenlydistributed protrusions deviate in a direction towards the back end edgeof the absorbent article. The protrusions on the back edge 53 of thecoherent area 51 are in the form of semi-circles extendinglongitudinally away from the front end edge of the absorbent article 1and towards the back end edge of the absorbent article. Hence, theprotrusions may be seen as half absorbent clusters 56, which arecontinuous with the coherent area 51.

FIG. 3 shows a cross-section taken along the line IV-IV in the frontportion of the absorbent component 50 shown in FIG. 2E. The oblong highdensity areas 60 are shown as thickened regions of the absorbentcomponent 50. After formation of the absorbent component 50 in a formingmold, the absorbent component 50 will usually be compacted between twocompaction rolls. As the amount of absorbent material is greater in theoblong high density areas 60, the density of the absorbent component 50will generally be higher within the oblong high density areas 60 than inthe areas of the absorbent component 50 located between and outside theoblong high density areas 60 unless measures are taken to avoidcompaction of the material in the oblong high density areas 60.

FIG. 4 shows a cross-section taken along the line V-V in the crotchportion of the absorbent component 50 shown in FIG. 2E. The absorbentcomponent 50 which is shown has two longitudinally extending andgenerally straight sealed channels 9,10 in which the upper core coverside 11 is joined to the lower core cover side 12 by seals 9′, 10′extending along the sealed channels 9,10, at the bottom of the sealedchannels 9,10. The seals 9′, 10′ may be provided as bond linesconsisting of bonding elements arranged in a bond pattern. A width ofeach bond line may be less than a width of the corresponding sealedchannel 9, 10 in which the bond line is arranged. Thereby, a slack isformed in the core cover material between the edge of the bond line andthe edge of the sealed channel in which the bond line is placed. Suchslack may be provided to allow expansion room for the absorbent materialarranged on either side of the bond lines. The slack may be smaller onthe inner side of each sealed channel 9,10 which is facing towards thecentre of the absorbent article, and larger on the outer side of eachsealed channel 9,10 which is facing towards the side edges of theabsorbent article 1.

Furthermore, a stiffening segment 13 is defined in the absorbentcomponent 50 between the sealed channels 9, 10. Two side segments 14 a,14 b are defined in the absorbent component 50 outside each sealedchannel 9, 10, between the sealed channel 9,10 and a corresponding sideseam 15, 16. Accordingly, the first side segment 14 a is positionedbetween the first sealed channel 9 and a first side seam 15, whereas thesecond side segment 14 b is positioned between the second sealed channel10 and a second side seam 16. The side seams 15, 16 are configured forjoining the upper core cover side 11 to the lower core cover side 12,suitably by means of ultrasonic welding, heat sealing, or the like.

As shown in FIG. 4, the absorbent component 50 is divided into astiffening segment 13 located between the sealed channels 9,10 and twoside segments 14 a, 14 b on either side of the stiffening segment 13.

FIG. 5 shows a cross-section taken through the conformance zone 55 alongthe line VI-VI in FIG. 2E. Three absorbent clusters 56 are shown in FIG.5. The absorbent clusters 56 are constituted by accumulations ofabsorbent material, such as a mixture of pulp fibers and superabsorbentmaterial which are separated by thinner portions of absorbent material.As disclosed herein, the absorbent clusters may alternatively becompletely separated by absorbent free channels between the absorbentclusters. The absorbent clusters may have a smaller thickness and alesser density than the coherent area of the in the crotch portion ofthe absorbent component. In particular, the absorbent clusters may havea smaller thickness and a lesser density than the oblong high densityareas.

With reference to FIG. 2F, the coherent area 51 of the absorbentcomponent 50 is a layer of absorbent material having uniform thickness.The conformance zone 55 is a contiguous conformance zone 55 which iscomposed of rod-shaped absorbent clusters 56 arranged spaced apart inthe transverse direction and in parallel to each other in thelongitudinal direction over a triangular area of the absorbent component50. The rod-shaped absorbent clusters 56 extend in the longitudinaldirection from the back edge 53 of the coherent area 51 and formcontinuations of the coherent area 51. Hence, the back edge 53 of thecoherent area 51 constitutes a straight base-line from which therod-shaped absorbent clusters 56 extend in a direction towards the backend edge (not shown in the figure) of the absorbent article.

With reference to FIG. 2G, the coherent area 51 of the absorbentcomponent 50 is a layer of absorbent material having oblong high densityareas 60 arranged therein. The oblong high density areas 60 extendgenerally all the way from the front edge 52 of the coherent area 51 tothe back edge 53 of the coherent area 51. The conformance zone 55 is anon-contiguous conformance zone 55 which is composed of circularabsorbent clusters 56 arranged in a regular, evenly distributed patternover a triangular area of the absorbent component 50.

With reference to FIG. 2H, the coherent area 51 of the absorbentcomponent 50 is a layer of absorbent material having oblong high densityareas 60 arranged therein. The oblong high density areas 60 extend inthe front portion of the coherent area 51, generally from the front edge52 of the coherent area 51 to the front ends of two sealed channels 9,10 which are arranged in the coherent area 51, as disclosed herein. Whencomparing the absorbent component 50 of FIG. 2H with the absorbentcomponent 50 of FIG. 2E, it can be seen that the oblong high densityareas 60 in FIG. 2H occupy a relatively smaller area of the absorbentcomponent 50 than in the absorbent component 50 shown in FIG. 2E.

Instead, the sealed channels 9 10 in FIG. 2H are longer than the sealedchannels in FIG. 2E. The sealed channels 9, 10 may optionally besupplemented by side seals as disclosed herein. The conformance zone 55is a contiguous conformance zone 55 which is composed of rod-shapedabsorbent clusters 56 arranged spaced apart in the transverse directionand in parallel to each other in the longitudinal direction over atriangular area of the absorbent component 50. The rod-shaped absorbentclusters 56 extend in the longitudinal direction from the back edge 53of the coherent area 51 and form continuations of the coherent area 51.Hence, the back edge 53 of the coherent area 51 constitutes a straightbase-line from which the rod-shaped absorbent clusters 56 extend in adirection towards the back end edge (not shown in the figure) of theabsorbent article.

With reference to FIG. 2I, the coherent area 51 of the absorbentcomponent 50 is a layer of absorbent material having uniform thickness.The conformance zone 55 is a contiguous conformance zone 55 which iscomposed of a set of rod-shaped absorbent clusters 56′ arranged spacedapart in the transverse direction and in parallel to each other in thelongitudinal direction over a first, rectangular area of the absorbentcomponent 50. Only two centrally arranged rod-shaped absorbent clusters56′ extend in the longitudinal direction from the back edge 53 of thecoherent area 51 and form continuations of the coherent area 51. Therod-shaped absorbent clusters 56′ on each side of the central rod-shapedabsorbent clusters are detached from the coherent area 56. Furthermore,the back edge 53 of the coherent area 51 constitutes a curved base-linefrom which the two centrally arranged rod-shaped absorbent clusters 56′extend in a direction towards the back end edge (not shown in thefigure) of the absorbent article. A second set of absorbent clusters56″, having a circular shape are arranged in a regular, evenlydistributed pattern over a generally D-shaped area of the absorbentcomponent 50. The second set of circular absorbent clusters 56″ isplaced further away from the back edge 53 of the coherent area 51 thanthe first set of rod-shaped absorbent clusters 56′.

As illustrated by the Figures, the plurality of absorbent clusters 56 inthe conformance zone 55 may comprise rod shaped clusters 56, 56′, therod shaped clusters 56, 56′ being arranged parallel to each other orgenerally parallel to each other in the longitudinal direction of theabsorbent article 1. The rod-shaped clusters 56 may be distributed inthe transverse direction over a triangular area of the absorbent core 5,the triangular area having its base arranged at the back edge 53 of thecoherent area 51 and its tip arranged on the central longitudinal axisy1 of the absorbent article and facing the back end edge of theabsorbent article 1.

The back edge 53 of the coherent area 51 may be non-linear, as shown inFIGS. 2E and 2I.

As disclosed herein, the absorbent article 1 may be provided withcomponents such as elastic barrier cuffs, elastic side panels, skin careagents, odour control material and other components which are commonlyused in absorbent articles such as for example baby diapers orincontinence garments. Such additional components are well known in theart and are not described in further detail here.

The disclosure may be varied within the scope of the appended claims.For example, the materials and dimensions used for the different layersforming the absorbent article 1 may be varied, as indicated above. Theabsorbent article may further include standing gathers, side panels,fastening systems etc. as known sealed channels 9, 10 in the art anddepending of the type of absorbent article intended.

EXAMPLES

Thickness, basis weight and density

The absorbent core (including the cover sheets) is carefully separatedfrom the other diaper components. The core is then placed flat for 24hours in a laboratory environment conditioned to 23° C. and 50% relativehumidity. Samples from the area of interest are then cut or punched fromthe core (including the cover sheets). Thickness is measured under apressure of 0.5 kPa. The thickness gauge foot should rest over thesample for about 5 seconds before reading the thickness value. Thesample is then weighed to the nearest milligram. The area of the samplecan be determined with a ruler. In case the sample contours areirregular, the sample can be photocopied or scanned, and the area can bedetermined with a planimeter or suitable image analysis software.

The basis weight (g/m²) is then obtained by dividing the sample weightby the sample area. The density (kg/m³) is obtained according to theformula sample weight/(sample thickness×sample area).

In case individual samples from the area of interest (e.g. ridges orclusters) vary with regards to thickness, basis weight or density, alarge number of samples are measured to obtain a representative mean.

Modified Circular Bend Stiffness

Modified Circular Bend Stiffness is determined by a test that ismodelled after ASTM D 4032-82 CIRCULAR BEND PROCEDURE. The test is wellknown in the absorbent article industry. The test is a simultaneousmulti-directional deformation of a material in which one face of aspecimen becomes concave and the other face becomes convex. The testgives a force value related to flexural resistance, simultaneouslyaveraging stiffness in all directions. The equipment has the followingparts: A smooth-polished steel plate platform measuring 102×102 mm, withthickness of 6.35 mm. In the center of the platform there is an orificewith an 18.75 mm diameter. A lap edge leads down to the orifice in a45-degree angle, to a depth of 4.75 mm (the remaining 1.6 mm to thebottom of the plate is vertical).

A plunger having an overall length of 72.2 mm, a diameter of 6.25 mm andball nose having a radius of 2.97 mm. A needle-point extends 0.88 mmfrom the nose (having a 0.33 mm base diameter, and a point with a radiusof less than 0.5 mm). The plunger is mounted concentric with the orificeand having equal clearance on all sides. The bottom of the plungershould be set well above the top of the orifice plate. From thisposition, the downward stroke of the ball nose is to the exact bottom ofthe plate orifice.

A tensile testing machine, capable of compression, such as Instron 5965from the Instron Corporation, Massachusetts, USA, is used for themeasurements. The machine is suitably arranged with a 10 Newton loadcell.

The absorbent core (including the cover sheets) is carefully separatedfrom the other diaper components. The core is then placed flat for 24hours in a laboratory environment conditioned to 23° C. and 50% relativehumidity. Samples measuring 37.5×37.5 mm are then punched from the areaof interest on the core (including the cover sheets). Bending or foldingof the samples must be avoided. In case the area of interest varies withregards to stiffness, a large number of samples are punched to obtain arepresentative mean.

A sample is centered on the orifice platform below the plunger such thatthe body facing side of the sample is facing the plunger. The plungerspeed is set at 500 mm/min. The plunger is actuated. The maximum forcereading to the nearest gram is recorded.

Measurements of core samples according to FIG. 2B comprising 78%superabsorbent and 22% cellulose fibers are disclosed in Table 1.

TABLE 1 The oblong high Absorbent clusters density areas in theconformance between the two The oblong high zone in the back channels inthe density areas in the part of the crotch portion of the front portionof the absorbent core coherent core coherent core Core Surface 400 790660 acc to weight FIG. 2B (gsm) Height 3.4 3.9 4.3 (mm) Density 117 200153 (kg/m³) Stiffness 33 155 87 (gf)

1. An absorbent article comprising an absorbent core sandwiched betweena liquid-permeable topsheet and a liquid-impermeable backsheet, saidarticle having a longitudinal direction along a central longitudinalaxis and a transverse direction along a central transverse axisextending perpendicular to said longitudinal axis, said absorbentarticle having a front end edge and a back end edge extending in saidtransverse direction and a first side edge and a second side edgeextending in said longitudinal direction, said absorbent articlecomprising a front portion, a back portion and a crotch portion locatedbetween said front portion and said back portion, wherein said absorbentcore comprises an absorbent component, said absorbent component beingenclosed by a core cover, said absorbent component comprising a coherentarea, said coherent area having an extension in said longitudinaldirection in at least said front portion and said crotch portion of saidabsorbent article and having an extension in said transverse directionover a full width of said absorbent component inside said core cover,said coherent area having a front edge and a back edge, said core covercomprising an upper side and a lower side, and a sealing arrangement forjoining said upper and lower sides of said core cover in the form of atleast one sealed channel extending in said longitudinal direction ofsaid absorbent core, said sealed channel being free or substantiallyfree from absorbent material, wherein the absorbent component comprisesoblong high density areas of absorbent material alternating with oblonglow density areas of absorbent material, the oblong high density areasof absorbent material and the oblong low density areas of absorbentmaterial extending in said longitudinal direction of said absorbentarticle, in the front portion and/or in the crotch portion of saidabsorbent article and wherein the absorbent component comprises 3-20oblong high density areas.
 2. The absorbent article according to claim1, wherein said oblong high density areas have a width of 3-30 mm. 3.The absorbent article according to claim 2, wherein the oblong highdensity areas have a length to width ratio of from 2 to
 135. 4. Theabsorbent article according to claim 1, wherein the absorbent componentcomprises oblong high density areas of absorbent material extending insaid longitudinal direction at least in the front portion and the crotchportion of said absorbent article.
 5. The absorbent article according toclaim 1, wherein the oblong high density areas extend in saidlongitudinal direction substantially from said front edge to said backedge of said coherent area.
 6. The absorbent article according to claim1, wherein said oblong low density areas have a width of from 0.5 mm to5 mm.
 7. The absorbent article according to claim 1, wherein the densityof the absorbent material in the oblong low density areas is less than50 kg/m³.
 8. The absorbent article according to claim 1, wherein thedensity of the absorbent material in the oblong high density areas is atleast 130 kg/m³ and below 300 kg/m³.
 9. The absorbent article accordingto claim 1, wherein the absorbent article comprises a single core layer.10. The absorbent article according to claim 1, wherein said backportion of said absorbent article further comprises a conformance zonewith absorbent material, the density of absorbent material is higher insaid oblong high density areas than in said conformance zone.
 11. Theabsorbent article according to claim 10, wherein said conformance zonecomprises a plurality of absorbent clusters.
 12. The absorbent articleaccording to claim 10, wherein a density of absorbent material is higherin said oblong high density areas than in said absorbent clusters insaid conformance zone in said back portion of said absorbent article.13. The absorbent article according to claim 10, wherein the density ofabsorbent material in said oblong high density areas is 10-90% higherthan in said plurality of absorbent clusters in said conformance zone insaid back portion of said absorbent article.
 14. The absorbent articleaccording to claim 10, wherein the density of absorbent material in saidoblong high density areas is 20-70% higher than in said plurality ofabsorbent clusters in said conformance zone in said back portion of saidabsorbent article.
 15. The absorbent article according to claim 1,comprising two sealed channels in the crotch portion of the absorbentarticle, the channels extending in the longitudinal direction of saidabsorbent core wherein a stiffening segment is defined in said absorbentcomponent between said sealed channels.
 16. The absorbent articleaccording to claim 15, wherein the density of absorbent material in saidstiffening segment in the crotch portion of said absorbent article is5-70% higher than in said oblong high density areas in the front portionof said absorbent article.
 17. The absorbent article according to claim10, wherein a modified circular bend stiffness is at least 50% higher inthe front portion of the absorbent article comprising oblong highdensity areas than in said conformance zone in the back portion of theabsorbent article.